US20160094111A1 - Method and apparatus for manufacturing laminated cores - Google Patents
Method and apparatus for manufacturing laminated cores Download PDFInfo
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- US20160094111A1 US20160094111A1 US14/863,736 US201514863736A US2016094111A1 US 20160094111 A1 US20160094111 A1 US 20160094111A1 US 201514863736 A US201514863736 A US 201514863736A US 2016094111 A1 US2016094111 A1 US 2016094111A1
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- iron core
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
- H02K15/02—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies
Definitions
- the present invention relates to a method and apparatus for manufacturing laminated cores by and with which both a laminated rotor core and a laminated stator core can be manufactured from a same strip material.
- Patent Literature 1 there is disclosed a method for manufacturing laminated cores for a stepping motor in which rotor core pieces and stator core pieces are sequentially punched out from a same strip material.
- Patent Literature 1 Japanese Unexamined Patent Application Publication No. H06-269149
- laminated rotor cores and laminated stator cores have the same lamination height (lamination thickness, numbers of iron core pieces laminated), however, depending on products, laminated rotor cores and laminated stator cores have different lamination heights in some cases. Besides this, in the case of hybrid-type stepping motors, a laminated rotor core in which a permanent magnet is held in between two laminated cores formed by laminating a plurality of iron core pieces is used, which sometimes requires a laminated rotor core having a lamination height that is shorter than that of a laminated stator core.
- the present invention has been made in view of the above circumstances, and an object thereof is to provide a method and apparatus for manufacturing laminated cores that are capable of improving material yield at the time of manufacturing both a laminated rotor core and a laminated stator core from a same strip material.
- a plurality of kinds of the laminated rotor cores can be manufactured from the strip material.
- the plurality of kinds of the laminated rotor cores can also be used for different electric motors.
- the plurality of kinds of the laminated rotor cores can also be in different shapes.
- the plurality of kinds of the laminated rotor cores can also be manufactured by laminating different numbers of the iron core pieces having a same shape.
- rotor core lamination dies that form the laminated rotor cores by punches in a same mold apparatus are provided in plurality.
- the plurality of the rotor core lamination dies each can also be index-rotated through rotating mechanisms for rotational lamination and by means of a single rotary drive source.
- the mold apparatus also has a stator core lamination die that forms the laminated stator core by a punch, and by means of the rotary drive source, the stator core lamination die can also be index-rotated in concert with the rotor core lamination dies.
- FIG. 1 is an explanatory diagram of a method for manufacturing laminated cores according to one embodiment of the present invention.
- FIG. 2 is an explanatory diagram of the same method for manufacturing laminated cores.
- FIG. 3 is an explanatory diagram of the same method for manufacturing laminated cores.
- FIG. 4 is an explanatory diagram of the same method for manufacturing laminated cores.
- FIG. 5 is a perspective view of a laminated rotor core manufactured using the same method for manufacturing laminated cores.
- FIG. 6 is a perspective view of a laminated stator core manufactured using the same method for manufacturing laminated cores.
- FIG. 7 is a schematic plan view of an apparatus for manufacturing laminated cores according to a first embodiment of the present invention.
- FIG. 8 is a schematic plan view of an apparatus for manufacturing laminated cores according to a second embodiment of the present invention.
- a plurality of iron core pieces 11 and 12 each are punched out from a same strip material 10 and laminated, and as illustrated in FIGS. 5 and 6 , when manufacturing both a laminated rotor core (a rotor) 13 and a laminated stator core (a stator) 14 , a plurality of additional iron core pieces 11 a are further punched out from the strip material 10 and laminated to manufacture a plurality of kinds of laminated rotor cores 13 and 13 a.
- a laminated rotor core a rotor
- stator a laminated stator core
- the laminated rotor cores 13 and 13 a and the laminated stator core 14 are ones for use in hybrid-type stepping motors (an example of electric motors).
- one of the laminated rotor cores 13 is for use with the laminated stator core 14 .
- Lamination heights (lamination thicknesses, numbers of iron core pieces to be laminated) of these laminated rotor core 13 and laminated stator core 14 are different from each other, and the laminated rotor core 13 is shorter (thinner) than the laminated stator core 14 .
- laminated rotor cores and laminated stator cores as long as the lamination height of a laminated rotor core is shorter than that of a laminated stator core, the laminated rotor core and the laminated stator core do not have to be limited to be used for the above-mentioned hybrid-type stepping motors, and can also be used for other electric motors.
- the other one of the laminated rotor cores 13 a is for use with other laminated stator cores.
- This other one of the laminated rotor cores 13 a can be used together with other laminated stator cores as is without increasing the number of iron core pieces to be laminated or in a state of having increased numbers of iron core pieces laminated.
- the laminated rotor core 13 a can also be used for electric motors other than the hybrid-type stepping motors.
- the plurality of kinds of laminated rotor cores 13 and 13 a to be manufactured from the same strip material 10 can be used for electric motors of a same kind, and can also be used for electric motors of different kinds.
- the laminated rotor cores 13 and 13 a can also have different shapes (structures) from each other.
- the term, different shapes refers to, for example, a case where the shapes of iron core pieces or layouts of caulkings and the like differ, a case where the shapes of the iron core pieces are the same, but the numbers of iron core pieces to be laminated are different, etc., depending on specifications of electric motors to be used.
- the above laminated rotor core 13 has two laminated cores 15 formed by laminating a plurality of iron core pieces 11 , and a permanent magnet 16 to be held in between the two laminated cores 15 .
- Each layer of the annular iron core pieces 11 forming the laminated rotor core 13 has an integrated structure that is not provided with connecting portions in a circumferential direction, however, each layer of the annular iron core pieces 11 can alternatively have a divided structure in which arc-like parts for iron core pieces can be connected with one other in an annular manner (the same applies to the iron core pieces 11 a forming the laminated rotor core 13 a ).
- the iron core pieces 11 adjacent to one another in a lamination direction are joined to one another using caulking portions 17 .
- these iron core pieces 11 can also be joined using welding or resin, or by a combination of two or more of these (the same applies to the iron core pieces 11 a ).
- a shaft hole 18 is formed in the center of the laminated rotor core 13 (the same applies to the laminated rotor core 13 a ).
- the laminated stator core 14 is formed by laminating a plurality of the iron core pieces 12 .
- Each layer of the annular iron core pieces 12 forming the laminated stator core 14 has an integrated structure that is not provided with connecting portions in a circumferential direction, however, each layer of these iron core pieces 12 can have a divided structure in which arc-like parts for iron core pieces can be connected with one other in an annular manner.
- the iron core pieces 12 adjacent to one another in a lamination direction are joined to one another using caulking portions 19 , however, these iron core pieces 12 can also be joined using welding or resin, or by a combination of two or more of these.
- the laminated stator core 14 has an annular yoke portion 20 , and magnetic pole portions 22 integrally connected to the inside of this yoke portion 20 and having a plurality of toothlets (slits) 21 formed at the tip portions.
- These yoke portion 20 and magnetic pole portions 22 each are formed by laminating the iron core pieces 12 each having a yoke piece portion 23 and magnetic pole piece portions 24 .
- These magnetic pole piece portions 24 are formed by punching out slots 25 with respect to the strip material 10 .
- a numeral 26 represents bolt holes that attach and fix the laminated stator core 14 .
- the plurality of kinds of the laminated rotor cores 13 and 13 a and the laminated stator core 14 described above are manufactured from the same strip material 10 in an order shown in FIGS. 1 to 4 .
- steps a to e in FIG. 1 is a step for manufacturing one of the laminated rotor cores 13 to be used with the earlier-described laminated stator core 14
- steps f to j in FIG. 2 is a step for manufacturing the other one of the laminated rotor cores 13 a to be used with the earlier-described other laminated stator cores. Since the steps a to e and the steps f to j are similar to each other, same components will be represented by same numerals. Since the step a for punching out temporary slots illustrated in FIG.
- step f for punching out temporary slots illustrated in FIG. 2 are the same, the step f for punching out temporary slots in FIG. 2 may be omitted, and the step a for punching out temporary slots in FIG. 1 may be used instead. In this case, the step f for punching out temporary slots will be an idle step.
- temporary slots 27 are punched out from a strip material 10 of an electromagnetic steel sheet having a thickness of, for example, approximately 0.15 to 0.5 mm (the step a for punching out temporary slots).
- pilot holes 28 for positioning are formed on both sides in a width direction of the strip material 10 at a predetermined pitch.
- caulking holes (through-holes) 29 in which caulking portions 17 are to be fitted are formed instead of forming the caulking portions 17 (a step b for forming caulking holes), and with respect to an area for punching out iron core pieces 11 which are the second and following to be laminated, the caulking portions 17 will be formed (a step c for forming caulking portions).
- a shaft hole 18 is also punched out in either of the steps b or c.
- the laminated rotor core 13 i.e., two laminated cores 15
- the laminated rotor core 13 is manufactured by sequentially laminating a plurality of the iron core pieces 11 punched out in the above steps a to e. Punching-out of the iron core pieces 11 necessary for the manufacture of the laminated rotor core 13 is then finished.
- steps for manufacturing the laminated stator core 14 punching-out of iron core pieces 12 illustrated in FIGS. 3 and 4 to be mentioned afterwards are performed.
- the lamination height of the laminated rotor core 13 is shorter than that of the laminated stator core 14 , a punch-out area for the iron core pieces 11 will have a surplus.
- manufacturing steps g to j in FIG. 2 are performed without performing the above-described punching-out of the iron core pieces 11 in the other steps b to e in FIG. 1 , and then the iron core pieces 11 a to be used for the manufacture of the other one of the laminated rotor cores 13 a are punched out.
- the iron core pieces 11 a are punched out (a step j for punching out iron core pieces).
- a layout of the caulking holes 29 and caulking portion 17 in the iron core pieces 11 a is different from the layout of the caulking holes 29 and caulking portions 17 in the iron core pieces 11 .
- steps k to t for manufacturing the laminated stator core 14 shown in FIGS. 3 and 4 are subsequently performed, and the iron core pieces 12 are punched out.
- FIGS. 1 and 2 the descriptions have been given on the cases where the iron core pieces 11 and 11 a in different shapes are punched out.
- iron core pieces in a same shape can also be punched out depending on, for example, a specification of an electric motor to be used.
- a laminated rotor core of a different kind than the laminated rotor core 13 can be manufactured.
- the iron core pieces illustrated in FIG. 2 can also be punched out without forming (omitting) the caulking holes and caulking portions illustrated in FIG. 2 .
- the laminated stator core 14 is manufactured from the strip material 10 having gone through the above manufacturing steps in FIG. 1 or the above manufacturing steps in FIG. 2 . Descriptions will be given hereunder on steps for manufacturing the laminated stator core 14 with reference to FIGS. 3 and 4 .
- the temporary magnetic pole piece portions 30 can thereby be extended toward the side of an axial center of the iron core pieces 12 . This step is omissible if not necessary.
- each of the temporary slots 27 is subjected to finish machining to form the slots 25 (a step m for completing slots).
- a tip of each of the temporary magnetic pole piece portions 30 is subsequently punched, and the magnetic pole piece portions 24 each having the plurality of toothlets 21 formed at the tip portion are formed (a step n for forming toothlets).
- Through-holes 31 composing the bolt holes 26 are formed at four corners of a punch-out area for the iron core pieces 12 (a step o for forming bolt holes).
- caulking holes (through-holes) 32 in which the caulking portions 19 are to be fitted are formed (a step p for forming caulking holes), and with respect to areas from which the iron core pieces 12 that are the second and following to be laminated are punched out, the caulking portions 19 are formed (a step q for forming caulking portions).
- the iron core pieces 12 After performing internal diameter punching (shaving-machining) with respect to inner circumferential surfaces after the iron core pieces 11 or iron core pieces 11 a have been punched out (a step r for punching out internal diameters), and after going through an idle step s, the iron core pieces 12 are punched out (a step t for punching out iron core pieces). By sequentially laminating a plurality of these punched out iron core pieces 12 , the laminated stator core 14 can be manufactured.
- a surplus area can be rid at the time of manufacturing both the laminated rotor core 13 and the laminated stator core 14 from the same strip material 10 , enabling an improvement in the material yield.
- This manufacturing apparatus 35 has, in a single mold apparatus, stations A to D where the step a for punching out temporary slots, the step b for forming caulking holes, the step c for forming caulking portions, and an idle step d are performed, and a station E where the iron core pieces 11 are punched out, which are as illustrated in FIG. 1 , stations F to I where the idle step f, the step g for forming caulking holes, the step h for forming caulking portions, and the idle step i are performed, and a station J where the iron core pieces 11 a are punched out, which are as illustrated in FIG.
- the station E is provided with a rotor core lamination die that forms the laminated rotor core 13 by a punch
- the station J is provided with a rotor core lamination die that forms the laminated rotor core 13 a by a punch
- the station T is provided with a stator core lamination die that forms the laminated stator core 14 by a punch.
- each of the stations E, J, and T is provided with one of rotating mechanisms for rotational lamination 37 to 39 rotating (index-rotating) the lamination dies by a predetermined angle.
- Each of the rotating mechanisms for rotational lamination 37 to 39 had one rotary drive source in the past, which has caused a problem of complication of features and control.
- This apparatus for manufacturing laminated cores 50 also has rotating mechanisms for rotational lamination 37 to 39 that punch down iron core pieces 11 , 11 a, and 12 inside lamination dies and rotationally laminate the iron core pieces 11 , 11 a , and 12 .
- the rotating mechanisms for rotational lamination 37 to 39 are connected to intermediate pulleys 51 to 53 through belts 54 to 56 , respectively, in a manner capable of being rotationally driven.
- the intermediate pulleys 51 to 53 are connected to a single rotary drive source 59 through a main belt 58 .
- a numeral 60 represents a tension pulley.
- a structure of the apparatus can thereby be made simple, and synchronization of a press and the rotating mechanisms for rotational lamination 37 to 39 can be made simple as well.
- the descriptions have been given on the case where the method and apparatus for manufacturing laminated cores of the present invention are applied to the manufacture of an inner-rotor type laminated core in which a laminated rotor core is placed with a space in between inside a laminated stator core.
- the method and apparatus for manufacturing laminated cores of the present invention can also be applied to the manufacture of an outer-rotor type laminated core in which a laminated rotor core is placed with a space in between outside a laminated stator core.
- a laminated rotor core to be used together with other laminated stator cores can alternatively have a divided structure in which arc-like parts for iron core pieces are connectable in an annular manner. In this case, it is also possible to punch out all of a plurality of parts for iron core pieces that become annular by being connected to one another from a surplus area in a strip material.
- caulking portions for laminated rotor cores and laminated stator cores round-shaped or V-shaped ones can be used, however, caulking portions in other shapes are also usable.
Abstract
At the time of manufacturing both a laminated rotor core 13 and a laminated stator core 14 by punching out a plurality of iron core pieces 11 and 12 from a same strip material 10 and laminating the punched out iron core pieces 11 and 12, respectively, a plurality of kinds of laminated rotor cores 13 and 13 a are manufactured by further punching out a plurality of iron core pieces 11 a from the strip material 10 and laminating the punched out iron core pieces 11 a. Here, the plurality of kinds of the laminated rotor cores 13 and 13 a can be used for different electric motors.
Description
- The present invention relates to a method and apparatus for manufacturing laminated cores by and with which both a laminated rotor core and a laminated stator core can be manufactured from a same strip material.
- In view of material yield, there is a method to manufacture both a laminated rotor core and a laminated stator core by punching out a plurality of iron core pieces from a same strip material and laminating them. For example, in
Patent Literature 1, there is disclosed a method for manufacturing laminated cores for a stepping motor in which rotor core pieces and stator core pieces are sequentially punched out from a same strip material. - Patent Literature 1: Japanese Unexamined Patent Application Publication No. H06-269149
- Normally, laminated rotor cores and laminated stator cores have the same lamination height (lamination thickness, numbers of iron core pieces laminated), however, depending on products, laminated rotor cores and laminated stator cores have different lamination heights in some cases. Besides this, in the case of hybrid-type stepping motors, a laminated rotor core in which a permanent magnet is held in between two laminated cores formed by laminating a plurality of iron core pieces is used, which sometimes requires a laminated rotor core having a lamination height that is shorter than that of a laminated stator core.
- In these cases, even if an improvement in material yield is attempted by manufacturing both a laminated rotor core and a laminated stator core from a same strip material as described earlier, a punch-out area for punching out iron core pieces for formation of a laminated rotor core has a surplus, and material yield lowers. Also, even if iron core pieces are punched out from the surplus punch-out area, laminated, and stored as stock, if there is no opportunity to use them, the stored iron core pieces will be disposed without any use, which consequently lowers the material yield.
- The present invention has been made in view of the above circumstances, and an object thereof is to provide a method and apparatus for manufacturing laminated cores that are capable of improving material yield at the time of manufacturing both a laminated rotor core and a laminated stator core from a same strip material.
- In order to achieve the above object, according to a method for manufacturing laminated cores of the present invention, in the method for manufacturing laminated cores in which a plurality of iron core pieces are punched out from a same strip material and laminated to manufacture both a laminated rotor core and a laminated stator core, a plurality of kinds of the laminated rotor cores can be manufactured from the strip material.
- In the case of the method for manufacturing laminated cores according to the present invention, the plurality of kinds of the laminated rotor cores can also be used for different electric motors.
- In the case of the method for manufacturing laminated cores according to the present invention, the plurality of kinds of the laminated rotor cores can also be in different shapes.
- In the case of the method for manufacturing laminated cores according to the present invention, the plurality of kinds of the laminated rotor cores can also be manufactured by laminating different numbers of the iron core pieces having a same shape.
- In order to achieve the above object, according to an apparatus for manufacturing laminated cores of the present invention, in the apparatus for manufacturing laminated cores in which a plurality of iron core pieces are punched out from a same strip material and laminated to manufacture both a laminated rotor core and a laminated stator core, rotor core lamination dies that form the laminated rotor cores by punches in a same mold apparatus are provided in plurality.
- In the case of the apparatus for manufacturing laminated cores according to the present invention, the plurality of the rotor core lamination dies each can also be index-rotated through rotating mechanisms for rotational lamination and by means of a single rotary drive source.
- In the case of the apparatus for manufacturing laminated cores according to the present invention, the mold apparatus also has a stator core lamination die that forms the laminated stator core by a punch, and by means of the rotary drive source, the stator core lamination die can also be index-rotated in concert with the rotor core lamination dies.
- In the case of the method and apparatus for manufacturing laminated cores according to the present invention, since a plurality of kinds of laminated rotor cores are manufactured at the time of manufacturing both laminated rotor cores and a laminated stator core from a same strip material, an area having been a surplus when manufacturing only a single kind of laminated rotor core can be used for the manufacture of other laminated rotor cores. Therefore, material yield can be improved.
- Also, in the case of the apparatus for manufacturing laminated cores, when intermittently rotating the plurality of the rotor core lamination dies and even the stator core lamination die by means of a single rotating mechanism for rotational lamination, miniaturization of the apparatus becomes increasingly possible.
-
FIG. 1 is an explanatory diagram of a method for manufacturing laminated cores according to one embodiment of the present invention. -
FIG. 2 is an explanatory diagram of the same method for manufacturing laminated cores. -
FIG. 3 is an explanatory diagram of the same method for manufacturing laminated cores. -
FIG. 4 is an explanatory diagram of the same method for manufacturing laminated cores. -
FIG. 5 is a perspective view of a laminated rotor core manufactured using the same method for manufacturing laminated cores. -
FIG. 6 is a perspective view of a laminated stator core manufactured using the same method for manufacturing laminated cores. -
FIG. 7 is a schematic plan view of an apparatus for manufacturing laminated cores according to a first embodiment of the present invention. -
FIG. 8 is a schematic plan view of an apparatus for manufacturing laminated cores according to a second embodiment of the present invention. - Next, with reference to the accompanying drawings, descriptions will be given on embodiments of the present invention for a better understanding of the present invention.
- As illustrated in
FIGS. 1 to 4 , in the case of a method for manufacturing laminated cores according to one embodiment of the present invention, a plurality ofiron core pieces same strip material 10 and laminated, and as illustrated inFIGS. 5 and 6 , when manufacturing both a laminated rotor core (a rotor) 13 and a laminated stator core (a stator) 14, a plurality of additionaliron core pieces 11 a are further punched out from thestrip material 10 and laminated to manufacture a plurality of kinds of laminatedrotor cores - The laminated
rotor cores stator core 14 are ones for use in hybrid-type stepping motors (an example of electric motors). - Here, between the plurality of kinds (here, it is two kinds) of the laminated
rotor cores same strip material 10, one of the laminatedrotor cores 13 is for use with the laminatedstator core 14. Lamination heights (lamination thicknesses, numbers of iron core pieces to be laminated) of these laminatedrotor core 13 and laminatedstator core 14 are different from each other, and the laminatedrotor core 13 is shorter (thinner) than the laminatedstator core 14. With regard to laminated rotor cores and laminated stator cores, as long as the lamination height of a laminated rotor core is shorter than that of a laminated stator core, the laminated rotor core and the laminated stator core do not have to be limited to be used for the above-mentioned hybrid-type stepping motors, and can also be used for other electric motors. - Moreover, the other one of the laminated
rotor cores 13 a is for use with other laminated stator cores. - This other one of the laminated
rotor cores 13 a can be used together with other laminated stator cores as is without increasing the number of iron core pieces to be laminated or in a state of having increased numbers of iron core pieces laminated. The laminatedrotor core 13 a can also be used for electric motors other than the hybrid-type stepping motors.
Here, the plurality of kinds of laminatedrotor cores same strip material 10 can be used for electric motors of a same kind, and can also be used for electric motors of different kinds. The laminatedrotor cores - As illustrated in
FIG. 5 , the above laminatedrotor core 13 has two laminatedcores 15 formed by laminating a plurality ofiron core pieces 11, and apermanent magnet 16 to be held in between the two laminatedcores 15. Each layer of the annulariron core pieces 11 forming the laminatedrotor core 13 has an integrated structure that is not provided with connecting portions in a circumferential direction, however, each layer of the annulariron core pieces 11 can alternatively have a divided structure in which arc-like parts for iron core pieces can be connected with one other in an annular manner (the same applies to theiron core pieces 11 a forming the laminatedrotor core 13 a). - The
iron core pieces 11 adjacent to one another in a lamination direction are joined to one another usingcaulking portions 17. However, theseiron core pieces 11 can also be joined using welding or resin, or by a combination of two or more of these (the same applies to theiron core pieces 11 a).
Additionally, ashaft hole 18 is formed in the center of the laminated rotor core 13 (the same applies to the laminatedrotor core 13 a). - As illustrated in
FIG. 6 , the laminatedstator core 14 is formed by laminating a plurality of theiron core pieces 12. Each layer of the annulariron core pieces 12 forming the laminatedstator core 14 has an integrated structure that is not provided with connecting portions in a circumferential direction, however, each layer of theseiron core pieces 12 can have a divided structure in which arc-like parts for iron core pieces can be connected with one other in an annular manner. Theiron core pieces 12 adjacent to one another in a lamination direction are joined to one another usingcaulking portions 19, however, theseiron core pieces 12 can also be joined using welding or resin, or by a combination of two or more of these. - The laminated
stator core 14 has anannular yoke portion 20, andmagnetic pole portions 22 integrally connected to the inside of thisyoke portion 20 and having a plurality of toothlets (slits) 21 formed at the tip portions. Theseyoke portion 20 andmagnetic pole portions 22 each are formed by laminating theiron core pieces 12 each having ayoke piece portion 23 and magneticpole piece portions 24. These magneticpole piece portions 24 are formed by punching outslots 25 with respect to thestrip material 10. Anumeral 26 represents bolt holes that attach and fix the laminatedstator core 14. - The plurality of kinds of the laminated
rotor cores stator core 14 described above are manufactured from thesame strip material 10 in an order shown inFIGS. 1 to 4 . - First, descriptions will be given on a step for manufacturing the laminated
rotor cores FIGS. 1 and 2 . Each of steps a to e inFIG. 1 is a step for manufacturing one of the laminatedrotor cores 13 to be used with the earlier-described laminatedstator core 14, and each of steps f to j inFIG. 2 is a step for manufacturing the other one of the laminatedrotor cores 13 a to be used with the earlier-described other laminated stator cores. Since the steps a to e and the steps f to j are similar to each other, same components will be represented by same numerals. Since the step a for punching out temporary slots illustrated inFIG. 1 and the step f for punching out temporary slots illustrated inFIG. 2 are the same, the step f for punching out temporary slots inFIG. 2 may be omitted, and the step a for punching out temporary slots inFIG. 1 may be used instead. In this case, the step f for punching out temporary slots will be an idle step. - As illustrated in
FIG. 1 ,temporary slots 27 are punched out from astrip material 10 of an electromagnetic steel sheet having a thickness of, for example, approximately 0.15 to 0.5 mm (the step a for punching out temporary slots). Here,pilot holes 28 for positioning are formed on both sides in a width direction of thestrip material 10 at a predetermined pitch. - Next, with respect to an area for punching out one of
iron core pieces 11 which is the first to be laminated, caulking holes (through-holes) 29 in whichcaulking portions 17 are to be fitted are formed instead of forming the caulking portions 17 (a step b for forming caulking holes), and with respect to an area for punching outiron core pieces 11 which are the second and following to be laminated, thecaulking portions 17 will be formed (a step c for forming caulking portions). Here, ashaft hole 18 is also punched out in either of the steps b or c. - Then, after going through an idle step (a step d in which punching-out is not performed), the
iron core pieces 11 are punched out (a step e for punching out iron core pieces). The laminated rotor core 13 (i.e., two laminated cores 15) is manufactured by sequentially laminating a plurality of theiron core pieces 11 punched out in the above steps a to e. Punching-out of theiron core pieces 11 necessary for the manufacture of thelaminated rotor core 13 is then finished. - With respect to the
strip material 10 finished with the punching-out of theiron core pieces 11, steps for manufacturing the laminated stator core 14 (punching-out of iron core pieces 12) illustrated inFIGS. 3 and 4 to be mentioned afterwards are performed. However, as described earlier, since the lamination height of thelaminated rotor core 13 is shorter than that of thelaminated stator core 14, a punch-out area for theiron core pieces 11 will have a surplus. - Accordingly, with respect to the
strip material 10 finished with the step a for punching out temporary slots inFIG. 1 , manufacturing steps g to j inFIG. 2 are performed without performing the above-described punching-out of theiron core pieces 11 in the other steps b to e inFIG. 1 , and then theiron core pieces 11 a to be used for the manufacture of the other one of thelaminated rotor cores 13 a are punched out. - Here, as illustrated in
FIG. 2 , after initially going through the idle step f and forming the above caulking holes 29 (a step g for forming caulking holes) or caulking portions 17 (a step h for forming caulking portions), and after going through an idle step i, theiron core pieces 11 a are punched out (a step j for punching out iron core pieces). A layout of the caulking holes 29 andcaulking portion 17 in theiron core pieces 11 a is different from the layout of the caulking holes 29 andcaulking portions 17 in theiron core pieces 11. - Then, by sequentially laminating the plurality of the punched out
iron core pieces 11 a, the other one of thelaminated rotor cores 13 a can be manufactured. - Since the punching-out of the
iron core pieces 11 a necessary for the manufacture of the other one of thelaminated rotor cores 13 a is thereby finished, with respect to thestrip material 10 finished with the punching-out of theseiron core pieces 11 a, steps k to t for manufacturing thelaminated stator core 14 shown inFIGS. 3 and 4 are subsequently performed, and theiron core pieces 12 are punched out. - The above punching-out of the
temporary slots 27, forming of the caulking holes 29, forming of thecaulking portions 17, and punching-out of theiron core pieces FIG. 1 excluding the step for punching out temporary slots and the manufacturing steps inFIG. 2 (operation and rest of a mold) is performed either manually or automatically. - In
FIGS. 1 and 2 , the descriptions have been given on the cases where theiron core pieces laminated rotor core 13 can be manufactured. In this case, since the forming of the caulking holes and caulking portions illustrated inFIG. 2 will be a same layout as that ofFIG. 1 , after forming the caulking holes and caulking portions illustrated inFIG. 1 , the iron core pieces illustrated inFIG. 2 can also be punched out without forming (omitting) the caulking holes and caulking portions illustrated inFIG. 2 . - Next, the
laminated stator core 14 is manufactured from thestrip material 10 having gone through the above manufacturing steps inFIG. 1 or the above manufacturing steps inFIG. 2 . Descriptions will be given hereunder on steps for manufacturing thelaminated stator core 14 with reference toFIGS. 3 and 4 . First, as illustrated inFIG. 3 , after going through an idle step k, basal part of each of temporary magneticpole piece portions 30 is subjected to coining (a step l for coining). The temporary magneticpole piece portions 30 can thereby be extended toward the side of an axial center of theiron core pieces 12. This step is omissible if not necessary. - Then, an outer circumferential surface of each of the
temporary slots 27 is subjected to finish machining to form the slots 25 (a step m for completing slots). - A tip of each of the temporary magnetic
pole piece portions 30 is subsequently punched, and the magneticpole piece portions 24 each having the plurality oftoothlets 21 formed at the tip portion are formed (a step n for forming toothlets). Through-holes 31 composing the bolt holes 26 are formed at four corners of a punch-out area for the iron core pieces 12 (a step o for forming bolt holes). - Next, as illustrated in
FIG. 4 , with respect to an area from which one of theiron core pieces 12 that is the first to be laminated is punched out, instead of forming thecaulking portions 19, caulking holes (through-holes) 32 in which thecaulking portions 19 are to be fitted are formed (a step p for forming caulking holes), and with respect to areas from which theiron core pieces 12 that are the second and following to be laminated are punched out, thecaulking portions 19 are formed (a step q for forming caulking portions). - After performing internal diameter punching (shaving-machining) with respect to inner circumferential surfaces after the
iron core pieces 11 oriron core pieces 11 a have been punched out (a step r for punching out internal diameters), and after going through an idle step s, theiron core pieces 12 are punched out (a step t for punching out iron core pieces).
By sequentially laminating a plurality of these punched outiron core pieces 12, thelaminated stator core 14 can be manufactured. - As seen from the above, by using the method for manufacturing laminated cores of this embodiment, a surplus area can be rid at the time of manufacturing both the
laminated rotor core 13 and thelaminated stator core 14 from thesame strip material 10, enabling an improvement in the material yield. - Next, with reference to
FIG. 7 , descriptions will be given on an apparatus for manufacturinglaminated cores 35 according to a first embodiment of the present invention. Thismanufacturing apparatus 35 has, in a single mold apparatus, stations A to D where the step a for punching out temporary slots, the step b for forming caulking holes, the step c for forming caulking portions, and an idle step d are performed, and a station E where theiron core pieces 11 are punched out, which are as illustrated inFIG. 1 , stations F to I where the idle step f, the step g for forming caulking holes, the step h for forming caulking portions, and the idle step i are performed, and a station J where theiron core pieces 11 a are punched out, which are as illustrated inFIG. 2 , and stations K to S where the idle step k, the step I for coining, the step m for completing slots, the step n for forming toothlets, the step o for forming bolt holes, the step p for forming caulking holes, the step q for forming caulking portions, the step r for punching out internal diameters, and the idle step s are performed, and a station T where the (stator)iron core pieces 12 are punched out and laminated, which are as illustrated inFIGS. 3 and 4 . Here, the station E is provided with a rotor core lamination die that forms thelaminated rotor core 13 by a punch, the station J is provided with a rotor core lamination die that forms thelaminated rotor core 13 a by a punch, and the station T is provided with a stator core lamination die that forms thelaminated stator core 14 by a punch. - With regard to the
iron core pieces rotational lamination 37 to 39 rotating (index-rotating) the lamination dies by a predetermined angle. Each of the rotating mechanisms forrotational lamination 37 to 39 had one rotary drive source in the past, which has caused a problem of complication of features and control. - In this embodiment, as illustrated in
FIG. 7 , power is transmitted to the rotating mechanism forrotational lamination 37 of the station E from an intermediate pulley (a toothed pulley, the same applies hereunder) 40 through a belt (a toothed belt, the same applies hereunder) 42, and power is transmitted to the rotating mechanism forrotational lamination 38 of the station J from an intermediate pulley (a toothed pulley, the same applies hereunder) 41 through a belt (a toothed belt, the same applies hereunder) 43. Theintermediate pulleys rotary drive source 45. The rotating mechanism forrotational lamination 39 of the station T obtains power for intermittent rotation from a differentrotary drive source 46 through abelt 47. Synchronized motion of the rotating mechanisms forrotational lamination - Next, descriptions will be given on an apparatus for manufacturing
laminated cores 50 according to a second embodiment of the present invention illustrated inFIG. 8 . Since stations A to D, F to I, K to S inFIG. 8 are the same as those inFIG. 7 , they are omitted inFIG. 8 . This apparatus for manufacturinglaminated cores 50 also has rotating mechanisms forrotational lamination 37 to 39 that punch downiron core pieces iron core pieces rotational lamination 37 to 39 are connected tointermediate pulleys 51 to 53 throughbelts 54 to 56, respectively, in a manner capable of being rotationally driven. Theintermediate pulleys 51 to 53 are connected to a singlerotary drive source 59 through amain belt 58. A numeral 60 represents a tension pulley. - Consequently, when the
rotary drive source 59 intermittently rotates as predetermined, the rotation is transmitted to the rotating mechanisms forrotational lamination 37 to 39 through themain belt 58,intermediate pulleys 51 to 53, andbelts 54 to 56, enabling the three rotating mechanisms forrotational lamination 37 to 39 to be synchronously driven in concert with operation of a mold. - A structure of the apparatus can thereby be made simple, and synchronization of a press and the rotating mechanisms for
rotational lamination 37 to 39 can be made simple as well. - The descriptions have been given hereinbefore on the present invention with reference to the embodiments, however, the present invention is not limited to the structures described in the above embodiments, and also includes other embodiments and variations conceivable within the scope of matters described in the scope of claims. For example, cases where the method and apparatus for manufacturing laminated cores of the present invention are composed by means of a combination of parts or all of each of the above embodiments and variations are also included in the scope of right of the present invention.
- In the above embodiments, the descriptions have been given on the case where the method and apparatus for manufacturing laminated cores of the present invention are applied to the manufacture of an inner-rotor type laminated core in which a laminated rotor core is placed with a space in between inside a laminated stator core. However, the method and apparatus for manufacturing laminated cores of the present invention can also be applied to the manufacture of an outer-rotor type laminated core in which a laminated rotor core is placed with a space in between outside a laminated stator core.
- Also, in the above embodiments, the descriptions have been given on the case where a plurality of kinds of laminated rotor cores manufactured from a same strip material each have an integrated structure having no connecting portions in a circumferential direction. However, for example, a laminated rotor core to be used together with other laminated stator cores can alternatively have a divided structure in which arc-like parts for iron core pieces are connectable in an annular manner. In this case, it is also possible to punch out all of a plurality of parts for iron core pieces that become annular by being connected to one another from a surplus area in a strip material.
- In the above embodiments, the descriptions have been given on the case where two kinds of laminated rotor cores are manufactured from a same strip material, however, depending on a lamination height of iron core pieces, it is also possible to manufacture three or more kinds of laminated rotor cores. An apparatus for manufacturing laminated cores in this case sometimes requires more stations having rotating mechanisms for rotational lamination.
- As caulking portions for laminated rotor cores and laminated stator cores, round-shaped or V-shaped ones can be used, however, caulking portions in other shapes are also usable.
-
- 10: strip material,
- 11, 11 a, 12: iron core piece,
- 13, 13 a: laminated rotor core,
- 14: laminated stator core,
- 15: laminated core,
- 16: permanent magnet,
- 17: caulking portion,
- 18: shaft hole,
- 19: caulking portion,
- 20: yoke portion,
- 21: toothlet,
- 22: magnetic pole portion,
- 23: yoke piece portion,
- 24: magnetic pole piece portion,
- 25: slot,
- 26: bolt hole,
- 27: temporary slot,
- 28: pilot hole,
- 29: caulking hole,
- 30: temporary magnetic pole piece portion,
- 31: through-hole,
- 32: caulking hole,
- 35: apparatus for manufacturing laminated cores,
- 37, 38, 39: rotating mechanism for rotational lamination,
- 40, 41: intermediate pulley,
- 42, 43: belt,
- 45, 46: rotary drive source,
- 47: belt,
- 50: apparatus for manufacturing laminated cores,
- 51, 52, 53: intermediate pulley,
- 54, 55, 56: belt,
- 58: main belt,
- 59: rotary drive source,
- 60: tension pulley
Claims (9)
1. A method for manufacturing laminated cores in which a plurality of iron core pieces are punched out from a same strip material and laminated to manufacture both a laminated rotor core and a laminated stator core,
wherein a plurality of kinds of the laminated rotor cores are manufactured from the strip material.
2. The method for manufacturing laminated cores according to claim 1 ,
wherein the plurality of kinds of the laminated rotor cores are used for different electric motors.
3. The method for manufacturing laminated cores according to claim 1 ,
wherein the plurality of kinds of the laminated rotor cores are in different shapes.
4. The method for manufacturing laminated cores according to claim 2 ,
wherein the plurality of kinds of the laminated rotor cores are in different shapes.
5. The method for manufacturing laminated cores according to claim 1 ,
wherein the plurality of kinds of the laminated rotor cores are manufactured by laminating different numbers of the iron core pieces having a same shape.
6. The method for manufacturing laminated cores according to claim 2 ,
wherein the plurality of kinds of the laminated rotor cores are manufactured by laminating different numbers of the iron core pieces having a same shape.
7. An apparatus for manufacturing laminated cores in which a plurality of iron core pieces are punched out from a same strip material and laminated to manufacture both a laminated rotor core and a laminated stator core,
wherein rotor core lamination dies that form the laminated rotor cores by punches in a same mold apparatus are provided in plurality.
8. The apparatus for manufacturing laminated cores according to claim 7 ,
wherein the plurality of the rotor core lamination dies each are index-rotated through rotating mechanisms for rotational lamination and by means of a single rotary drive source.
9. The apparatus for manufacturing laminated cores according to claim 8 , wherein the mold apparatus also has a stator core lamination die that forms the laminated stator core by a punch, and by means of the rotary drive source, the stator core lamination die is index-rotated in concert with the rotor core lamination dies.
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JP2015162963A JP6316783B2 (en) | 2014-09-25 | 2015-08-20 | Manufacturing method and manufacturing apparatus of laminated iron core |
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US10284058B2 US10284058B2 (en) | 2019-05-07 |
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US10284058B2 (en) * | 2014-09-25 | 2019-05-07 | Mitsui High-Tec, Inc. | Method and apparatus for manufacturing laminated cores |
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CN105871084B (en) * | 2016-05-03 | 2018-10-30 | 腾普(常州)精机有限公司 | A kind of excitation component and manufacturing method of generator |
WO2019172161A1 (en) * | 2018-03-08 | 2019-09-12 | 日本電産株式会社 | Method for producing rotor core member |
CN115512957B (en) * | 2022-11-01 | 2023-03-24 | 宁波震裕科技股份有限公司 | Method for manufacturing multi-sheet step type E-shaped iron core |
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CN105471196A (en) | 2016-04-06 |
US10284058B2 (en) | 2019-05-07 |
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